MAV Case IH AFX Series Complete Chopper Installation Guide

Transcription

1 MV ase IH FX Series omplete hopper Installation Guide S _V0_June_2016

2 ase IH FX Series omplete Redekop MV hopper Installation Manual Table of ontents Section Safety 0 Pre-Installation 1 Hydraullic Line Modifications 2 Sieve xtension 3 Internal Deflectors 4 Factory Knifebar and oncave Setting 5 Straw Door 6 hopper Placement 7 Gas Springs and Speed Sensor 8 Ladder 9 Drive 10 Drive Shield 11 Hydraulic Oil Level 12 2

3 ase IH FX Series omplete Redekop MV hopper Installation Manual omponent Reference 2. Hydraulic Lines 3. Sieve xtension 4. Internal Deflectors Factory Knifebar & oncave Setting 9 6. Straw Door 7. hopper 8. Gas Springs & Speed Sensor 9. Ladder hopper Drive 11. Drive Shield 12. Hydraulic Oil Level Tailboard 3

4 Supplies required to assist during the installation procedure: Requirements: Marker Drill Drill bit - 9mm dia or 11/32 in dia. - required for section 3.3, Drill bit - 10mm dia or 13/32 in dia. - required for section 4.2 Drill bit - 12mm dia or 1/2 in dia. - required for section 3.1 Pipe Sealant Tape - required for section 2 Sand paper / emery cloth - required for section 10.5 Straight dge or Laser lignment Tool - approx mm long - required for section 10 Grinder - required for section 3.1 Purchase Purchase V elt from NH Parts: NH # V elt 3 x 107L Kevlar HD or NH # V elt 3 x 107L Kevlar - required for section

5 0 Safety 0.1 Introduction IMPORTNT: Read through this instruction thoroughly and familiarize yourself with the machine before removing these components. Do not skip steps or perform them out of order. This instruction manual explains the proper procedure for preparing the combine and removing the Factory Spreader omponents in order to install the Redekop MV hopper 0.2 Recognize Safety Information This is a safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. 0.3 Understand Signal Words signal word - DNGR, WRNING, or UTION - is used with the safety-alert symbol. DNGR identifies the most serious hazards. WRNING or UTION safety signs are located near specific hazards or precautionary areas in this manual. 0.4 Follow Safety Instructions arefully read all safety messages in this manual and on your machine. Keep safety signs in good condition. Replace missing or damaged safety signs. e sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your dealer. There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator s manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life. If you do not understand any part of this manual and need assistance, contact your dealer. Other languages are available for this machine. Please contact Redekop 5

6 0.5 Safe Operating Practices DO NOT stand near combine when machine is running. LWYS refer to your ombine Operator s Manual, and review Safety section before operating machine. The ombine Operator s Manual details safe operating practices that must be followed to protect you and others from accidental death and/or injury. Operate machine only when all guards are correctly installed. efore moving away, always check immediate vicinity of machine (e.g. for children). nsure adequate visibility. Use the horn as a warning immediately before moving away. When making turns, always take into consideration the width of the attachment and the fact that the rear end of the machine swings out. ttachments and ground conditions affect the driving characteristics of the combine. Never leave machine unattended as long as engine is running. 0.6 Work In Ventilated rea ngine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. 0.7 Practice Safe Maintenance Understand service procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet, and clothing from powerdriven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. llow machine to cool. Securely support any machine elements that must be raised for service work. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. On self-propelled equipment, disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine. 6

7 0.8 void ontact With Moving Parts Keep hands, feet and clothing away from power driven parts. Never clean, lubricate or adjust machine when it is running. 0.9 void High-Pressure Fluids Inspect hydraulic hoses periodically at least once per year for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately. scaping fluid under pressure can penetrate the skin causing serious injury. void the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. ny fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source Use Proper Lifting quipment Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual. nsure lifting equipment is rated for the job nsure operator is appropriately licensed to operate lifting equipment 7

8 0.12 Personal Protective quipment (PP) Qualified Person designated by the employer, who is knowledgeable about and familiar with all relevant specifications and assembly instructions and is capable of identifying existing or potential hazards in surroundings or working conditions which may be hazardous or dangerous to employees shall determine appropriate Personal Protective quipment required for this assembly. Personal Protective quipment (PP) are devices worn by the employees to protect against hazards in the environment. xamples include safety glasses, face shields, respirators, gloves, hard hats, steel-toe shoes, and hearing protection. Torque Table Nominal Size lass 8.8 lass 10.9 Nm / (ft-lbs) Nm / (ft-lbs) M8 - flanged 27 / (20) 39 / (29) - non flanged 25 / (18) 35 / (26) M10 - flanged 54 / (40) 57 / (42) - non flanged 49 / (36) 70 / (51) M12 - flanged 93 / (69) 134 / (98) - non flanged 85 / (63) 121 / (90) M16 - flanged 231 / (171) 331 / (244) - non flanged 210 / (155) 301 / (222) heck all fasteners to ensure they have been properly tightened 8

9 Kit ontent Ref Item Name Part # Qty ase IH hopper ssy Handle, ase IH FX S206 x1 x1 hopper Drive Shield S884 x1 D Straw Door 57L S136 x1 Sieve xtension H518 x1 F Jackshaft ssembly 3 FX Drive S711 x1 FX 120S Drive ompletion ox - 3 Drive FX Sheave PTO Driver ox - 3 Drive FX 120S Hyd. Non-Windrow ox FX ompletion ox FX Ladder omponents D F 9

10 1 Pre-Installation 1.1 On the driver side of the combine: - Loosen belt tensioners () on the main drive belts - Remove belts () and sheave () 1.2 Rotate spreader to rearward position to prepare for removing spreader package (D) D 1.3 Disconnect chaff spreader proximity sensor (upper driver side) Disconnect spreader speed sensor (lower passenger side) ut cable ties for proximity switches and speed sensor Remove spreader speed sensors from hydraulic motors (D1) D1 D1 10

11 1.4 Remove spreader hydraulic hoses () from hydraulic block (F) F or F Swing hose assembly () back onto spreader for storage 1.5 If hydraulic block (F) is located in the rear zone as shown in dotted box, it will interfere with the new jackshaft and will have to be removed Disconnect steel hydraulic lilnes (F1) from hydraulic block (F1) F Remove hydraulic block (F) from combine wall F 11

12 1.6 Loop hydraulic circuit Install new hydraulic rubber hose (J) into steel hydraulic lines (F1) to loop circuit F1 J Install new hydraulic rubber hose (J) into hydraulic block (F) to loop circuit or F F J 12

13 1.7 Remove gas spring (K) K Gas Spring is under load and will extend when released Remove sensor (L) - Save sensor for chopper assembly later M L 1.8 Place a pallet under spreader and lift into place with a fork lift to assist in removal of the spreader Remove pin and bolt (M) from one side and rest spreader on pallet to remove hardware from opposite side Lower pallet with spreader and store in a convenient location 1.9 Remove internal deflector panels (N) N N 13

14 1.10 Remove straw door (P) - leave factory straw door brackets for mounting Redekop straw door Remove Ladder ssembly - ensure ladder is in upper position (R) - remove gas shocks (R1) - keep for reinstallation on new ladder - remove straw door hinge (R2) - remove support brackets (R3) - drop ladder - remove bottom hinge bolt (R4) - remove top ladder plastic roller support (front) - carefully swing out ladder from supports and lower to the ground P R R1 R2 R3 R4 14

15 1.11 Remove spreader mount panels (S), (S1) & (S2) S S1 P S2 15

16 1.12 Remove bolts from flange (U) to prepare for chopper assembly 1.13 The inside panels should look like this after spreader, straw door, and delfector panels are removed (V) U 1.14 Disconnect hydraulic hose at (Y) ssemble 90 degree fittings (Z) - Steel 90 Degree Hydraulic Fitting (# H FFX) 10 FORSX-10MORF (Z) x ttach fittings (Z) to factory fitting (Y) Reattach hose to fittings (Z) - This moves the hose out of the way for the chopper belt drive V Y Z Z 16

17 2 Hydraulic line modifications 1 Reference: - Pump 1 - Pump onnection - Hydraulic Steel Tube (to be removed) 1 - Hydraulic Steel Tube onnection - Hydraulic Steel Tube lamp D - Hydraulic Hose Return Line onnection - Hydraulic line (fan side) F - Upper Internal ccess Panel G - Internal hopper Rotor H - Sieve D 1 F G H 17

18 2.1 Hydraulic line changes at PTO parts located in S849S Hydraulic Kit ox ** If available - use vacuum at reservoir to reduce oil leakage ** Parts List: HH112 Hydraulic Hose.625 x 148L (I) Qty 1 H99-12 Hose lamp.75 (L) Qty 8 H99-14 Hose lamp.875 (M) Qty 8 H99-18 Hose lamp (N) Qty 6 H99-20 Hose lamp 1.25 (P) Qty 4 I L M N P Lay plywood (H1) on top of sieve (H) to prevent damaging sieve (H) Remove upper access panel (F) ** Nuts are not welded on combine at rear of panel, use caution not to lose them ** - to be reinstalled - keep all factory hardware F H1 F Remove hose clamps () securing steel hydraulic line () running from pump () on outer combine wall to connection () in upper access area - qty as required 18

19 2.1.4 Remove hose clamps () securing hydraulic steel line () on outside of left combine wall (drive side). - qty as required In combine upper access panel - Quickly disconnect hydraulic steel line () from fan side hydraulic line () at fitting (2) - have a container ready to catch any fluid that may leak - plug end of steel line removed or drain fluid in line after disconnecting onnect new hydraulic rubber hose (I) to line () at fitting (2) - HH112 Hydraulic Hose.625 x 148L I Quickly disconnect steel hydraulic line () from pump () at fitting (1) - have a container ready to catch any hydraulic fluid that may leak out from the steel line () or pump () - plug end of steel line removed or drain fluid in line after removing

20 2.1.8 Disconnect outter hydraulic steel line () from inner hydraulic steel line at fitting (1) - not to be reused Inner 2 Outter Rotate inner hydraulic steel line () and pull through left combine side wall - not to be reused Place new hydraulic rubber hose (I) from connection (2) up along upper access edge (J) to the outside thru left combine side wall hole (same direction as previous steel line) I J Place new hydraullic rubber hose (I) along the existing steel line () up to the pump () I I 20

21 onnect new hydraulic rubber hose (I) to pump () at fitting (1) - have a container ready to catch any hydraulic fluid that may leak out from the pump () 1 I Re-attach factory hose clamp bracket (K) to new hydraulic rubber hose (I) at connection (2) in upper access 2 K1 I ut plastic (K1) in half from steel line hose clamp being replaced K Place over hose and in between steel clamp for hose protection K ssemble hose clamp.75 (-12) (L) and (-18) (N) together qty 4 with: - M8 x 20 flange bolt and flange nut (L1) N L1 L L In upper internal access area, install hose clamp assembly (N) onto hydraulic rubber hose (I) and secure clamp (L) to hydraulic steel line () I N L Install 2 clamp assemblies at each corner (J1) J1 J1 21

22 Install hose clamp (-18) (N) onto hydraulic rubber hose (I) above upper access (J2) in the middle of opening - connect to factory clamp (K1) I N J2 K1 I N Install hose clamp assemlby (-18) (N) x2 onto hydraulic rubber hose (I) and secure clamp.75 (-12) (L) to hydraulic steel lines () x2 - ensure clamps are tight and hose is not rubbing on any moving parts L N L N I L N 22

23 Reinstall factory hose clamp () to hydraulic steel lines () and to hydraulic rubber hose (I) I I 23

24 Secure PTO Gearbox Return Tube Parts List: S874 Strap FX sump line - lack (M) Qty 1 H99-20 Hose lamp 1.25 (P) Qty 1 M P Secure PTO Gearbox Return Tube (N1) to combine tensioner bracket (N2) with Strap (M) N2 N1 M N N nsure PTO Gearbox Return Tube (N1) is 110mm (4 inches) max from PTO Reservoir (N) - tap tube (N1) into PTO Reservoir (N) as required (tube is held into reservoir by a pressue fit o-ring and can be pushed or pulled in or out of the reservoir easily) M M N1 N 110 mm (4 inches) MX. Tap in tube (N1) 24

25 ttach strap (M) to bottom of combine tensioner mount bracket (N2) with: - M8 x 25 flange bolt and flange nut (M1) ttach hose clamp (-20) (P) to tube (N1) and fasten to clamp (M) with: - M8 x 25 flange bolt and flange nut (M1) N2 M M1 P N1 View from above - looking down N2 M1 M M1 P N1 View from below - looking up 25

26 2.2 Return Line hanges If equipped with hydraulic knifebar valve () ** This procedure is easiest when upper internal access panel is removed ** parts located in S849S Hydraulic Kit ox Parts List: H17-10 Fit Hyd Plug Hex 10 MORFS (3) Qty 1 RP743 Fit Hyd 90deg 10 MORFS-10FORFSX () Qty 3 H FOFS Fit Hyd Tee 10 MORFS-10 MORFS (3) Qty 1 HH114 Hydraulic Hose.5 x 57L (F) Qty Disconnect hyd hose () from tee fitting () - have pail ready to catch oil flow from disconnected hose - LRG FLOW!! 3 3 F Insert new hydraulic cap (3) into hydralic hose () just disconnected to stop oil flow from hydraulic reservoir tank Disconnect steel hyd line (D) from knifebar valve () - have pail ready to catch oil flow from hyd line (D) Drain steel hyd line (D) Disconnect steel hyd line (D) from tee fitting () D Remove hose clamp (D1) from steel hyd line (D) D Remove steel hyd line (D) - not to be reused Disconnect tee fitting () from hyd line/fitting (1) D 26

27 Reference illustrating hydraulic steel tube (D) being removed D1 D ssemble hydraulic fittings into configuration as shown () onnect new hydraulic fitting assembly () end () to hyd line/fitting (1) 1 27

28 2.2.9 onnect new hydraulic rubber line (F) to new hydraulic fitting assembly () at end (2) onnect new hydraulic rubber line (F) to hydraulic knifebar valve () - use same routing as hydraulic steel line (D) just removed F 2 F 2 F onnect hydraulic hose () from reservoir tank to new hydraulic fitting assembly () at end (4) - quickly remove plug (1) from end of hose () and connect to minimize oil leakage Orientate fittings () in line with belt 4 28

29 2.3 Return Line hanges parts located in S849S Hydraulic Kit ox Parts List: If NOT equipped with hydraulic knifebar valve () (relocation of reservoir hydraulic line) H17-10 Fit Hyd Plug Hex 10 MORFS (1) Qty 1 RP743 Fit Hyd 90deg 10 MORFS-10FORFSX () Qty Disconnect factory hydraulic line (2) from tee fitting (J) - have oil pail ready - LRG FLOW!! Install hydraulic plug (1) into end of hose (2) to stop oil flow J onnect 90 degree hydraulic fittings () x2 together 29

30 2.3.5 onnect hydraulic fittings ()() to tee (J) - rotate fittings down onnect hydraulic hose (H) to fitting () H J nsure all connections are tight Orientate fittings (G) in line with belt (G1) Secure hydraulic hose (H) - use tie straps and tube clamps G1 G H Reinstall upper access panel (F) with existing ase IH Hardware F F 30

31 3 Sieve xtension Installation 3.1 ttach left hand sieve reinforcement bracket () - if necessary grind welds flush on sieve frame () to fit bracket properly in place. e sure bracket fits tight up against sieve wall. - Grind reinforcement bracket to fit around existing welds () if necessary. - Drill 2 holes (1/2 dia.) at (D) and 1 hole at () in sieve wall - olt into place with: - M12 x 25 flange bolt and flange nut x7 D 3.2 On right hand side remove bolt (F) Install sieve reinforcement bracket (1) over slide bracket (G) 1 G F G F 1 31

32 For 7120 Series Only 3.3 ttach sieve extension mounts (J) left and right to combine grain loss monitor bracket (K) on both sides. Drill 11/32 hole on the grain loss monitor bracket and bolt mount into place. olt up from bottom on upper flange (L) with: - M8 x 25 flange bolt and flange nut (L1) x8 K J J L J L1 32

33 3.5 ttach belting assembly (N) to sieve extension mounts (J) with: - M8 x 16 round head bolt and flange nut (J1) x4 N J1 J J N J N M 33

34 3.6 Sieve xtension Installation For 8120, 9120 Series Only Parts List: parts located in S857S Installation Parts Kit S484 Sieve xtension ssy FX () Qty Remove existing nuts and flat washers (3) x4 from bottom of grain losss monitor pan () Install sieve extension assembly () to the bottom of grain loss monitor pan () on to existing bolts (2) Mount side of sieve extension assembly () to combine side bracket (1) with: - M6 x 16 flange bolts and flange nuts (1) x Use existing flat washers and nuts (3) x4 to mount to the existing bolts (2) through the grain loss monitor pan () (2 on each side) Installed sieve extension () view 34

35 4 Internal Deflectors eater 4.1 Mark location for fin mount plates () on combine beater pan edge () as per diagram. 4.2 Drill 4-13/32 holes in combine beater pan lip. Fasten fin mount plates flush with bottom of pan lip (See top illustration for placement from combine sidewall.) Two left and two right fins are provided. If combine is used, look at wear pattern on roof. Fasten deflector fins () to mounting plates and adjust as necessary using fins required. Residue must be evenly distributed across the width of the chopper. Proceed to rotate knifebar all the way out, lower chopper concave as much as possible, and set internal chopper on high speed. Fasten with: 6" Plan View 36" pproximate location create6 an even feed o chopper. djust as ne 4 pcs. - olt, Flg M10 x 20 (Plate) 4 pcs. - Nut, Flg M10 8 pcs. - olt, Flg M8 x 20 (Fin) 8 pcs. - Nut, Flg M8 NOT: ach user may be required to adjust these fins, due to different crop conditions. Side View Default View 35

36 5 Factory Knife ar & oncave Setting 5.1 The internal straw chopper can be operated in two speeds. Squeeze the plates () together to allow the collar to slide. Slide out for low speed and slide in for high speed. Make sure collar is locked in place (uses dentent balls). Note: When equipped with a Redekop MV chopper the internal chopper must always be set to operate at high speed. The factory stationary knife adjust handle () can be adjusted to vary the height of the stationary knives. With the handle down, the knives are fully engaged. With the handle up, the knives are removed. 1 Replace bracket () with new S838Z Notched Knifebar djustment racket (1) - this limits engagement of the stationary blades to 25%. For best rock protection, open concave up as much as possible, however if you wish to chop with both choppers adjust concave clearance to a minimum of 10mm (3/8 ). Use the concave adjusting bolts (D) to set the clearance () to a minimum of 10 mm (3/8 ) between the concave and the tip of the rotor blade. D 1 36

37 6 Straw Door Installation 6.1 Use existing brackets and hardware from the factory strawdoor () when mounting the Redekop straw door (). ssemble the straw door handle and place to the rear with: - M10 x 35 flange bolt and flange nut x2 6.2 Install handle guide bracket () and spacer (D) on both sides Mount Handle (F) in place If straw door doesn t operate smoothly check for binding against hardware. - Place straw door in the rearward position () to mount chopper into place - Handle (F) x1 - M12 id Spacer (D) x2 - M12 x 35 flange bolt x4 - M12 flange nut x4 F D D F 37

38 7 hopper Installation 7.1 Remove hood bolts () and loosen gusset bolts () - Spread hood gusset () a minimum of 0.25 apart. hopper flange must slide between plates for mounting. 7.2 Place a second pallet (D) under the MV chopper bundle and turn 90 degrees Remove tailboard shipping brackets and rest tailboard against the loader to ensure it does not strike the combine during mounting Raise chopper to the combine using a fork lift or front end loader () from the back 7.3 Slide upper chopper flange along combine hood flange (F). lign hood flange holes with chopper flange slots and replace hood bolts () with: 8 - olt M12 x Nut M Washer, Flt M12 D 7.4 Tighten gusset bolts () and torque to specification. fter gussets have been tightened retorque chopper mount bolts. F 38

39 8 Gas Springs & Speed Sensor Installation 8.1 Mount gas springs () to tailboard and chopper housing - both sides, with: - M8 x 16 flange bolt (1) x Install speed sensor () to sensor mount bracket () Mount sensor pick-up lug (F) onto the chopper shaft - sensor () was previously removed from the hydraulic spreader motor Note: nd of sensor must be within 1-2mm of sensor tooth. F 8.3 ttach sensor harness (1) to existing wire extension (D) 1 D 8.4 Install speed sensor shield cover () over speed sensor with: - M6 x 16 flange bolt (1) x4 1 39

40 9 Ladder ssembly Installation 9.1 Install the proximity sensor and mount bracket () removed from the factory spreader onto the upper wall. - the sensor will point to nothing 9.2 Install outer () and inner () link mount brackets onto top of chopper rear wall location (D) with: - M8 x 20 round head bolts and flange nuts (1) x16 - ensure the head of the bolt is on the inside of chopper - do not tighten yet 1 D 9.3 Install ladder support mount () on rear of chopper rear wall between tailboards with: - M8 x 25 round head bolts and flange nuts (1) x2 - ensure the head of the bolt is on the inside of chopper 1 40

41 9.4 Install ladder parallel link frame and handle - ensure there are nylon bushings (x4) installed in pivot tube J1 J K Place parallel link frame (F) in between link mount brackets (&) aligned with pivot hole Insert pivot pin (G) through pivot hole in mount brackets (&) and frame (F) - both sides G H K2 K Secure pivot pin (G) in place with, - M8 x 50 hex head bolt and lock nut (G1) x2 - both sides G H Tighten link mount brackets (&) in place Install ladder mount link extension (H) to plate on parallel link frame (F) with: - M8 x 25 flange bolts and flange nuts (H1) x4 G1 F Install handle pivot bracket (J) over extension tube (H) and attach to right side wall of chopper with: - M8 x 16 round head bolts and flange nut (J1) x4 L1 M M1 L lign the ladder pivot handle (K) with the hole on plate (J) and slide into extension tube (H) aligning with roll pin hole (K1) Hammer in.313 x 1.5in roll pin (K2) at location (K1) to hold handle in place 9.5 ttatch angle plate (L) to the center tailboard mount () with: - M8 x 20 flange bolts and flange nut (L1) x2 9.6 ttach 3 shims (M) on ladder pivot frame (F) with: - M8 x 35 round head bolt and flange nut (M1) x2 L 9.7 Install ladder proximity sensor (N) as shown onnect harness (N1) together N1 N 41

42 9.8 Install Ladder Rollers Tie ladder up Remove existing rollers () x4 from top of ladder and replace with new rollers () x4 9.9 ttach ladder to parallel link frame (F) Rotate chopper tailboards down Lower ladder ttatch ladder to pivot tube with: - existing plastic blocks (D) and hardware D F 9.10 Install gas springs Rotate ladder up G Install the two large gas springs () removed from the factory spreader to the inner link mount bracket () and frame (F) Install the short gas spring (G) to the inner link mount bracket () and frame (F) F 42

43 9.11 Glamour Panel Installation Remove glamour panel () from the mount brackets on ladder Remove glamour panel mount brackets () from the ladder Install new glamour panel support brackets () to ladder mount plate (1) Install glamour panel () to new support brackets () - adjust alignment of the glamour panel to the rear corner panels with the adjustment holes in the mount brackets Ladder Step xtension Installation Place the ladder extension (D) to the ladder bottom step and mark holes to be drilled through Drill 11/32 holes (D1) x2 in the ladder bottom step Install ladder step extension (D) to bottom step with: - M8 x 20 round head bolt and flange nut (D2) x2 - ensure the head of the bolt is on top of the step D2 D1 D 43

44 9.13 Handrail Installation Hold handrail () up near top of ladder and fasten in place with short handrail mount (F) x2 with: - M8 x 20 round head bolt and flange nut (F1) x4 - handrail is on the outside of ladder, the mount brackets are on the inside Fasten bottom leg of handrail in place with long handrail mount (G) x2 with: - M8 x 20 round head bolt and flange nut (G1) x4 - ensure bracket is pointing below the ladder F F1 F Install ladder rail support brace (H) to long handrail mounts (G) with: - M8 x 20 flange bolt and flange nut (H1) x2 G G1 H1 H 44

45 Note: When lowering the ladder the Redekop hopper tailboards must be in the lowered position. 45

46 10 hopper Drive 3 Jackshaft Installation parts located on pallet and in S771S ox part located on a pallet in S531S Kit Parts List: S772 Gusset JackShaft Mount - lack () Qty 1 S771 Jackshaft FX 3 230/240S ssy () Qty 1 RP918 Sheave FX PTO 3 () Qty 1 RP387 Sheave SK (F) Qty 1 S784 Spring ssy Weld Int hopper HS (G) Qty 1 388K Velt 3 88L Kevlar (K) Qty K Velt 3 144L Kevlar (L) Qty 1 K G L F 46

47 10.1 Top Jackshaft support gusset installation Parts List: part included in S771S ox S883 Upper Jackshaft Mount FX 20S ttach Upper JackShaft Mount () on the outside of left combine side wall thru existing holes with: Hardware included in S825S Kit - M12 x 30 flange olt M12 x 30 and flange nut (2) x Jackshaft FX 3 Install Parts List: part located on a pallet in S531S Kit S771 Jackshaft FX 3 230/240S ssy () Qty Lift Jackshaft () into place - recommend to use a hoist or lifting device 47

48 Mount jackshaft assembly () in place by attaching lower bracket (1) to combine replaced gusset from the Step (8.X) with: Hardware included in S825S Kit - M12 x 30 round head bolt and flange nut (2) Qty Round head bolts (2) have to be mounted on inside of combine Secure top mount bracket (4) to the gusset jackshaft mount () with: Hardware included in S825S Kit - M12 x 30 flange bolt and flange nut (5) x

49 10.3 Sheave FX PTO 3 Installation Parts List: part located in RP918S Kit RP918 Sheave FX PTO 3 () Qty Outer elt Removal Loosen Tension Rod (2) Remove Tension Rod (1) D Remove outer belt () NH # to be modified for future reinstallation Inner elt Removal from drive pulley Remove inner belt () from drive pulley (D) - leave loose, do not remove from combine Outer elt Modification ut one (1) groove off of 3 groove belt () NH # to make this into a 2 groove elt - to be reinstalled for the ase internal chopper slow speed drive 49

50 Drive Pulley Removal Remove center bolt (D1) from drive pulley (D) D1 D Remove upper drive pulley (D) using a gear puller (D2) - not to be reused D D Replace center bolt and washer (D1) onto shaft (D3) D1 D nsure key (D4) remains in shaft (D3) - secure key in place with tape if required D4 50

51 Install new 3 Sheave () with: - existing hardware - ensure key is in place heck for clearance between back of sheave () and flange on rear gusset after sheave is tightened If flange is to long, grind down flange to provide clearance heck learance Remove tension rod assembly (1) Remove plastic spacer (3) from tension rod assembly (1) Reinstall plastic spacer (3) on to new spring tensioner assembly (G) 3 G 51

52 10.4 Spring Tensioner ssembly Installation for Internal High Speed OM hopper elt Parts List: part included in S771S Kit S784 Spring ssy Weld Int hopper HS (G) Qty 1 - ensure plastic spacer (3) from existing tensioner (1) is reassembled onto this new tensioner G Mount Spring ssy Weld Int hopper HS (G) on the internal drive pulley shaft with: - re-use factory hardware M10 x 45 flange bolt and lock nut (G1) x1 G *Tighten nut (G1), to touch clevis but still turn freely * G2 Install spring assembly with spacer (G2) on clevis as shown (towards outside) for belt clearance G1 G1 G G 52

53 10.5 Install sheave on chopper rotor shaft Install 3 sheave (F) with 50mm bushing (F1) on to chopper rotor shaft (G) with: - ensure 14 x 9 x 50mm key (F3) is in place - do not tighten until alignment procedure below is complete F3 F1 G F lign (F2) sheave (F) on rotor shaft to sheave (1) on jackshaft with a straight edge (F2) or laser alignment tool Tighten sheave (F) into place after alignment procedure 1 ** reference ushing Installation procedure 10.6 for correct bushing installation ** F F2 53

54 10.6 USHING Installation IMPORTNT: DO NOT US LURINTS IN THIS INSTLLTION To Install ushing: 1. Remove all paint, oil grease, etc. from tapered surface of bushing and bore of mating part. 2. See Standard mounting assembly - Figure 1. NOT: If bushing does not slide freely on shaft, wedge a screwdriver blade into the saw cut and the flange OD to open the bore of the bushing. aution: xcessive wedging will split the bushing. 3. Standard Mount Slide bushing on shaft, flange first. If using the setscrew, snug it against the key. xcessive Torque will cause mating part to be eccentric. Position mating part in place on bushing aligning drilled holes in mating part with tapped holes in bushing flange. Using lock washers, install capscrews thru the mating hub and into the bushing flange. (Note: S bushings can only be Standard Mounted. e sure the three tapped holes in the mating hub do not align near the bushing saw cut. If they do, rotate the bushing 60 degrees.). 4. Use Torque Wrench. Tighten all capcrews evenly and progressively in rotation to the torque value listed in the table. xcessive wrench torque, closing the gap between the bushing flange and mating hub, or the use of lubricants will break the mating hub. To Remove ushing: 1. Loosen and remove all capscrews. 2. For Standard Mount, thread capscrews into tapped holes in mating part to jack against bushing flange. Tighten bolts evenly and progressively in rotation to separate the two components. 3. Loosen setscrew to slide bushing from shaft. Standard Mounting Fig. 1 Screw Tightening Information Tapered Size & Thread Torque to pply ushing of abscrew Ft-Lbs Nm SK 5/ SF 3/

55 10.7 Install Drive elts Parts List: belts to be installed Purchase V-elt,3 Rib x 107L (J) Qty 1 - this is a new belt purchased from NH parts J K V-elt,3 Rib x 3045mm L (K) Qty 1 - this belt has 1 groove cut off to make it a 2 rib belt belts located in S771S Kit 388K Velt 3 x 88L (L) Qty K Velt 3 x 144L (M) Qty 1 L M Install new internal chopper high speed belt (J) to inside of factory sheave () and inside 3 grooves of upper sheave (J3) - this is a new belt purchased from NH parts - # V elt 3 x 107L Kevlar HD or - # V elt 3 x 107L Kevlar J J lign jackshaft sheave (J4) to upper sheave (J3) with a straight edge (J5) or laser alignment tool - tighten into place once aligned J3 ** reference ushing Installation procedure 10.6 for correct bushing installation ** djust idler wheel (L2) alignment if necessary J4 L2 J5 55

56 Install V belt 3 x 88L (L) onto the upper sheave (J3), route around idler (L2) and install on to sheave (J5) on jackshaft J3 L L2 J Re-install V belt 2 x 3045L (K) onto the upper sheave (J3) outter grooves and to large drive sheave () on combine - this belt is the 3 groove factory belt removed and then cut down to a 2 rib belt - keep the cut edge of the belt facing out J3 K Install V belt 3 x 144L (M) onto chopper sheave (F) and to inner sheave (1) on jackshaft, route around idler (2) 1 M 2 F 56

57 djust tension on belts: Tighten all belts by adjusting spring tensioners: - elt J - with spring tensioner (J1) - ensure plastic spacer is in place - elt K - with spring tensioner (K1) - elt L - with spring tensioner (L1) - elt M - with spring tensioner (M1) K2 J2 L L2 K J K1 J1 L1 M1 M2 M 57

58 To adjust the tension on the belt, the idler needs to be adjusted to apply the correct tension to the belt To apply idler tension (K2, L2, M2), adjust nut (T1) on tension rod (K1, L1, M1) to tighten spring (T2) until it lines up with the spring indicator (T3) - typical for all belts except J T2 T1 J1 T To apply idler tension (J2), adjust nut (T1) on tension rod (J1) until indicator (T3) lines up with the end of the rod T1 J1 T3 58

59 11 Drive Shield Installation 11.1 ssemble drive shield mount brackets () with: - M8 x 20 flange bolt and flange nut x Mount assemblies (1) into locations (,, & D) with: - M8 x 16 flange bolt x2 - M8 x 16 round head bolt x1 - M8 flange nut x3 1 D D D D 59

60 11.3 Mount bracket () on the bottom of jackshaft lower mount bracket with: - M8 x 16 flange bolt and flange nut (1) x Install drive shield (G) over mounted brackets () and () with - M8 x 16 flange bolt (H) x5 G G H H 60

61 12 Hydraulic Oil Level HK HYDRULI FITTINGS FOR LKS DO NOT RUN TH OMIN WITHOUT HYDRULI OIL 12.1 heck the hydraulic oil level before starting and moving the combine. Oil level can be checked through the sight glass () located on the top rear deck. The oil level should at a minimum reach the bottom of the sight glass If necessary, add oil through filler opening () Reference combine operator s manual for exact instructions 61

62 nsure that the Hydraulic Fittings have been tightened HK HYDRULI FITTINGS FOR LKS HYDRULI LINS MY UNDR PRSSUR scaping fluid under pressure can penetrate the skin causing serious injury. void the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. DO NOT RUN TH OMIN WITHOUT HYDRULI OIL Wear Hearing Protection during operation heck all fasteners to ensure they have been properly tightened When starting chopper, be sure all people are clear of the rear of the combine Start threshing module in low speed and listen for clearance problems. If a knocking noise is heard, stop the machine immediately! Fix problem and repeat procedure. Progress to full power when everything is running smoothly at lower speeds. 62

63 Torque Table Nominal Size lass 8.8 lass 10.9 Nm / (ft-lbs) Nm / (ft-lbs) M8 - flanged 27 / (20) 39 / (29) - non flanged 25 / (18) 35 / (26) M10 - flanged 54 / (40) 57 / (42) - non flanged 49 / (36) 70 / (51) M12 - flanged 93 / (69) 134 / (98) - non flanged 85 / (63) 121 / (90) M16 - flanged 231 / (171) 331 / (244) - non flanged 210 / (155) 301 / (222) heck all fasteners to ensure they have been properly tightened 63

64 WRRNTY RD Please send this warranty card in to Redekop Manufacturing Fill in when the Straw hopper has been fully installed and the following items have been checked mail to: or Fax to: Selling Dealer Name and Location: ustomer Name: ddress: ountry: Telephone #: mail: ombine Model # ombine Serial # Strawchopper Serial # Jackshaft Serial # Date Strawchopper installed: Strawchopper installed by: Print: elt Tensioners set to spring indicator Strawchopper Rotor has been rotated manually to ensure clearances: Strawchopper lades clear with the knifebar: Fan lades clear rotating through the shroud : ombine has been run with the threshing module in low speed and then progressed to full power when everything is running smoothly at lower speeds? re there any knocking noises? omments: 64